Nonaqueous battery

ABSTRACT

Batteries in which the cathodes are electronically conducting lamellar compounds of graphite are described. Fabrication is carried out by preparing a discharged battery having a reinforced pyrolytic graphite cathode, a nonwoven polypropylene cloth separator, an anode substrate and an electrolyte solution of a suitable lithium salt in either dimethyl sulfite or propylene carbonate between the cathode and anode and then charging the battery to cause an electronically conducting lamellar compound of graphite to be formed as the cathode and lithium to be precipitated as the anode on the anode substrate.

United Sttes Patent [191 Bennion et al.

[451 Oct. 29, 1974 NONAQUEOUS BATTERY [7 3] Assignee: The United States of America as represented by the Secretary of the Navy, Washington, DC.

[22] Filed: July 7, 1972 [21] Appl. No.: 269,902

[52] US. Cl...; 136/6 LN, 136/122 [51] Int. Cl. H01m 35/02 [58] Field of Search 136/6 LN, 100, 122

[56] References Cited UNITED STATES PATENTS 3,423,242 l/l969 Meyers et al..... [36/6 .LN 3,484,296 12/1969 Brizzelli l36/l00 R 3,542,602 11/1970 Gabano l36/l00 R Maricle et al l36/l00 R X Dey [36/6 LN Primary Examiner-Winston A. Douglas Assistant Examiner-C. F. Lefevour Attorney, Agent, or FirmR. S. Sciascia; Roy Miller; Lloyd E. K. Pohl [5 7] ABSTRACT Batteries in which the cathodes are electronically conducting lamellar compounds of graphite are described. Fabrication is carried out by preparing a discharged battery having a reinforced pyrolytic graphite cathode, a nonwoven polypropylene cloth separator, an anode substrate and an electrolyte solution of a suitable lithium salt in either dimethyl sulfite or propylene carbonate between the cathode and anode and then charging the battery to cause an electronically conducting lamellar compound of graphite to be formed as the cathode and lithium to be precipitated as the anode on the anode substrate.

5 Claims, No Drawings BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to nonaqueous batteries. More; particularly, this invention relates to nonaqueous bat-1 teries having positive electrodes of electronically conducting lamellar compounds of graphite. 5

2. Description of the Prior Art Room temperature, nonaqueous, high voltage cells. have failed to become economically useful devices ei-g ther because they are subject to chemical shorting, i.e., the oxidizing agent in the cathode is too soluble and dif-? fuses to the negative discharging the cell internally, or because there is no viable transfer mechanism to allowi for rapid enough discharge. While certain compounds iof graphite such as graphite oxide have been suggested: *for use as depolarizers for primary batteries using aqueous electrolyte solutions, this suggestion has never been. seriously pursued.

SUMMARY OF THE INVENTION A series of organic solvent-lithium salt systems were? investigated resulting in the discovery of an electrode: system having high voltage on open circuit, modest power density and high energy density. Among the key. features of this invention is the use of an electronically conducting graphite electrode positive which has a large surface area. It has been found that pyrolyticj graphite, with its very nearly perfect lamellar crystall structure performs better than other forms of very pure.- carbon. The best performing electrolyte solution is Li-i ClO dissolved in dimethyl sulfite (DMSU). Other salts. such as LiCF S and LiBF, dissolved in dimethyl sulfite have also been found to perform well as electro-f mixture of approximately 50 percent by volume powdered graphite and 50 percent by volume powdered K 80 The cup had a volumeof about 0.5 cm. The

negative electrode was a strip of Al. The electrodes: were about 1 cm apart and separated by the glass frit :which was 1 cm in diameter and 1 mm thick.

A numer of charging attempts were made at 200 to '400uA for periods of to minutes. The open circuit potential was about 4.0 volts, but not steady, following these charge periods. Currents of ZOOuA could ibe drawn from the cell at between 3.0 and 2.5 V.

These experiments led to further investigation diirected toward the discovery of more promising positive ielectrode materials. The observation of such a high potential suggested more study of the system. It was concluded that the K 80 probably was not being converted to K S O at any appreciable rate but that some other reaction yielded the high potential. The graphite used in the Pt cup was traced and found to be some scrap left over from building a nuclear reactor.

EXAMPLE 2 i A cell was constructed using the system Cu/LiCF- 1 80 DMSU/Graphite. Chips of Li O impregnated activated charcoal were pressed into holes drilled in the graphite. The graphite was grade Rl Great Lakes Carbon Co. Nuclear Graphite. The electrodes were plates held by Teflon nuts and bolts and separated by small Teflon washers through which the bolts passed. A test of the cell was performed in a dry nitrogen atmosphere '}glove box. A constant current of 5mA was passed with lytes. It has further been found that LiClO dissolved .propylene carbonate (PC) produces nearly the same electrolyte behavior as the LiClO, dimethyl sulfite; solution. The negative electrode substrate may be lith-. ium metal or a base material such as copper, aluminum,{ stainless steel, nickel or graphite upon which lithium metal is deposited.

The negative electrode may be porous, with high internal surface area, or it may be in the form of a wire, screen or sheet.

a medium glass frit, was filled with a dimethyl sulfiteg (DMSU) solution saturated with LiF, LiPF and Licopper as the cathode. The overall electrode area was 4 cm. A deposit of gray metal (assumed to be lithium) was observed on the copper. An open circuit potential 'of 3.9 V was observed and a 5mA discharge was obtained at about 2.2 V. When 50mA charge currents were used, a flat charging voltage plateau at 6.55 V was observed with no bubbling present at either electrode. Discharges at 5mA showed two voltage plateaus, at 4.25 volts and 2.5 volts. A summary of the series of constant current charges and discharges run is shown in the Table. After the tests were run, the electrodes were removed from the small glass cell and from the dry box. The copper based electrode bubbled vigorously when placed in water, indicating the presence of lithium. The graphite electrode seemed to be pitted and somewhat flaky on the surface but was otherwise intact.

I The activated charcoal had been impregnated with :LiOH and then heated to l,000 C. in vacuum. Later experiments indicated that under these conditions most lof the LiOH was simply vaporized and probably very CIQ The positive electrode was a Pt c up filled with a.

little LiOH was converted to U 0.

TABLE DMSU/GRAPHITE CELL CYCLE CH0 OPEN DISCHG DISCHG COUL MIDPOINT VOLTAGE NO. TIME CUR- CIRCUIT CURRENT TIME EFF.

(min) RENT VOLTAGE (mA) (min) ('70) CHG DIS I 4.53 50 4.65 5 I83 40.6 6.55 2.75 2 2.66 50 4.60 5 l l.2 42.2 6.55 2.75 3 2.07 50 4.60 10 4.92 47.6 6.55 2.75 4 6.89 50 4.70 50 2.56 37.] 6.55 2.75 5 3.74 20 4.60 20 5.26 68.5 5 3.75 6 12.30 20 4.70 20 6.10 54.4 5.45 3.75

'A. LiClO Propylene Carbonate PERFORMANCE DATA FOR A 4cm Li(Cu)LiCF SO DMSU/GRAPHITE CI ELL CYCLE CH CH6 OPEN DlSCHG DlSCHG COUL M1D1 o1g1T VOL A E N0. TIME CUR- CIRCUIT CURRENT TlME EFF.

(min) RENT VOLTAGE (mA) (min) 70) G110 DIS EXAMPLE3 after charging. Discharge voltages at 2mA/cm A galvanostatic polarization curve was obtained for; each electrode in the system Li/DMSU, LiCF sO l- Graphite. A strip of copper was used as the substratel on which to deposit lithium. The graphite was grade" R-l Great Lakes Carbon Co. Nuclear Graphite. Thej concentration of LiCF SO in DMSU was 1.4 molar at C. The lithium salt was prepared from Ba(CF SO and was recrystallized twice from acetone. An Ag/Ag-' C10 reference electrode was used to measure the po-i tential of each electrode. The graphite electrode.

sphere dry box with no recirculation provision. A bas-j ket of molecular sieves were in the box to trap mois-; ture. No visible nitride or oxide formation was observed on the lithium immersed in the solution during the few hours taken to run the experiment. The cell container used was an open beaker. i

EXAMPLE 4 A series of single cells were tested to determine if the'i previously observed high voltage cells could be dupli-f cated in different solvent-electrolyte systems. All tests were done using as-received reagent grade chemicals.- Lithium ribbon negative and nuclear reactor grade graphite positive electrodes were used. These tests? were done in a dry argon atmosphere glove box. The- 0 results of the tests were as follows:

This electrolyte gave very similar behavior to that observed with LiClO DMSU. Flat charge and dis-g charge voltage-time curves were obtained at constant? currents. Open circuit voltages of 4.5 volts and above; were observed and a lmA/cm discharge above 4.4 volts was obtained for a one hour period. Flash currents of nearly 60 mA/cm were obtained.

B. LiNO Propylene Carbonate This system gave a cell clearly inferior to the previous system. Open circuits after charging were below 4.0 volts and declined rather rapidly with time. A lmA/cm discharge for only 4 minutes drove the cell voltage to" 6 below 2.0 volts. C. LiSCN DMSU This solution appears to attack lithium metal and; t rn t qpqnsir u sof 2-8.. ..Y9ltw. obser dropped to 2.0 volts in only 5 minutes. D. LiClO -n-nitrosodimethyl amine Avery flat charge curve at about 4.5 volts was ob .tained at 4mA/cm The open circuit voltage was less than 3.9 volts and discharge voltages at 2mA/cm dropped below 2.0 volts within 5 minutes. E. LiNO DMSU The behavior of this electrolyte was very similar to the LiNO propylene carbonate cell. No high voltage cell was observed. F. LiBF DMSU This system has been observed to yield the high voltage produce in the same manner as the LiClO DMSU system. Open circuit voltages of 4.5 volts have been obtained, but extended charge and discharge tests have been hampered by lithium dendrite formation. G. A series of salts were tested for gross solubility in DMSU.

If soluble, such salts would have been tested as battery cell electrolytes in a manner similar to the above (A-F) tests. The salts found to be insoluble to any large extent are LiBO Li CO LiCl, Li SiO LiPO Li SO U 0 and U 0 While these salts may be useful in electrodes of other types, their insolubility in DMSU precludes their use in batteries such as those under consideration here using DMSU as the solvent.

The above tests show some guidelines to the prediction of whether a given electrolyte-solvent system will form the lithium-graphite high voltage electrochemical cell. The criteria may be summarized as follows:

1. The electrolyte salt must be soluble in the solvent.

potentials with respect to lithium. The salts LiNO and LiSCN apparently fail in this respect while Li- CIO., and LiBF are apparently suitable.

4. Useful batteries are possible only if the conductance of the electrolyte solution is reasonably high. The conductance of a solution of 1.64 moles of Li- ClO per Kg of DMSU was found to be 5.72 X 10 mhl/cm which is sufficiently high.

EXAMPLE 5 Single cell charge and discharge tests were done on a Li/LiClO (sat.) DMSU/graphite cloth cell. The tests *were done in an argon filled glove box in a test cell with a si taoslsar a of 5 It was found that a high voltage product was formed. The charge-discharge curves were not as flat as those of previous tests. Coulombic efficiencies for four runs were 68 percent, 77 percent, 66 percent and 59 per-' cent for 20 minute charge times at 2mA/cm lt was found that the typical open circuit after charge was between 45 and 5 volts and that most of the discharge at constant current of 2mA/cm was above 3.5 volts cell potential.

At the time of the tests, it was felt that one reason for the fairly low capacity of the cell was that the graphite cloth was not completely graphitized by the manufac: turer. Additional annealing above 3,000 C. was accomplished in a vacuum furnace powered by induction for 30 rriinute s was carried out above 3.5 volts. Flash currents of 70mA/cm were observed.

1 It was observed that the solution in the glass cell remained clear throughout the tests, with small crystals 5 of LiClO, present in the bottom of the cell. No bub- 10 of structural stability as well as performance.

Later, this same piece of RPG was put back into a" .cell and three cycles covering several days were real-;

ized. The final cycle was an 11 hour charge at. ]5mA(-lmA cm lfollowed'by a 4 hour'discharge coils. Tests on samples of graphite cloth which hadi}. 5 Effl0mA(-2rru r/crrfi) to a cutoff voltage of 3. 5 V.

been subjected to this treatment fer fourliours showed no significant improvement over the as-received cloth; It was concluded that either the cloth cannot be completely graphitized or that the capacity of the graphite? for charge retention is fairly low (about 60 coul/gm).

EXAMPLE 6 7 Early tests in LiClO, DMSU systems used graphite" electrodes obtained from scrap pieces of Great Lakes;

EXAMPLE 7 in a glass cell (6.4 cm X 3.9 cm X 0.7 cm) by a fine Pt .wire. Strips of A1 6.4 cm X 2.0 cm X 0.0125 cm were placed on either side of the RPG. Nonwoven polypropylene cloth 0.0076 cm thick (Kendall Corp., Grade No. E1451 was used as a separator. The cell was filled Carbon p y grade graphite used in a e with DMSU and a large excess of ucro, The DMSU reactor. (These scrap pieces had not been subjected to radiation.) it was found that these electrodes tended toZ disintegrate as charging took place, although not an ex-i tent sufficient to cause complete cell failure. A moref durable and perhaps more porous form of graphite was sought. I

A material described in the Super Temp Engineering Handbook of Pyrolytic Materials as RPG (Reinforcedl Pyrolytic Graphite) was tried. RPG is formed by im-l pregnating a carbon felt with pyrolytic carbon depos-l ited from methane at l,850 to 2,050 F. lt is possible! to control the porosity of the final product by impreg-l nating for longer or shorter periods of time. The pyro-l lytic carbon is then converted to graphite at 3,000 C.';

-were recorded for currents of 2mA/cm. The curves 0 were quite flat both on charge and discharge. Each dis-l charge was carried to a sharp break in the voltage-time.

curve which occurred near 3.8 volts. Open circuits were approximately 4.4 volts with the majority of the discharge above 4.0 volts. Charging voltages were ap-- proximately 4.6 volts. Coulombic efficiencies for the cell increased as the number of cycles increased. For the first eight cycles the efficiencies were 56 percent, 73 percent, 87 percent, 87 percent, 89 percent 85 per- .99nt95, Es eem.ans1 BsI E---- After a 17.5 hour charge at lmA/cm", the open cir-; cuit voltage was 4.55 volts and quite stable. A dis charge of 2mA/cm was carried out at 4.4 volts for 10,

minutes. Then a l0mA/cm discharge was carried out;

During this discharge the voltage dropped from 4.0 volts to 2.5 volts Open circuit voltage returned quickly lg fl volts stable for 3 hours. A 2rnft/crn disg liarg e had been vacuum distilled after contacting with chromatographic grade Linde 5A molecular sieves. Only material with conductivity less than 10* mho/cm (about 80 percent middle cut) was retained. Water, content by Carl Fischer titration was less than 50 ppm. The LiClO had been recrystallized from acetone and chloroform and vacuum dried.

The cell was cycled 33 times, 1 hour charge and 1 hour discharge. The charge was at 34mA, the discharge 35 fat 8mA. Typical charge voltage was 4.85V and typical discharge voltage 4.5V.

On disassembly, the RPG electrode was swollen but was still approximately rectangular with dimensions 5.7 cm X 2.7 cm X 0.104 cm. By comparison to original dimensions the overall or superficial volume changed from 0.923 cm to 1.601 cm or an increase of 74 percent. The RPG was still very porous to water.

EXAMPLE 8 A cell was built with two pieces of RPG (4.67 cm X 1.82 cm X 0.0915 cm) placed opposite each other in a narrow cell. Polypropylene nonwoven cloth was used as a separator. A sheet of aluminum (5.7 cm X 2.12 cm X 0.0173 cm) was put on the other side of the central (positive) RPG electrode. The electrolyte was DMSU saturated with excess LiClO The cell was open and inside the dry box described above which had no recirculation of gas.

The first 19 cycles were between the two RPG electrodes. Charging was 1 hour at l6mA(-2.8mA/cm followed by discharge through 240 ohms. The discharge was above l5mA for 45 minutes when the potential fell below 3.5V. The coulombic efficiency was between percent and percent. The 20th and 21st cycles were operated at 30mA charge (-5.3mA/cm for 1 hour followed by discharge through a ohm resistor. The cell potential was very similar to that described in Example 6. The geometric area was about 5.65 cm The RPG negative always ran a little positive of a lithium wire reference electrode as measured with a Hewlett-Packard Model 3440A digital voltmeter or a Kendal 9.491.6 .0 3 e w e r- The RPG negative showed almost no physical change" while the positive was slightly warped such that the edges were further away from the negative.

EXAMPLE 9 Other tests, similar to those described in Examples 1 through 8, confirmed that LiCF SO or LiBF, dissolved in either DMSU or propylene carbonate perform well, as electrolyte solutions. These tests further revealed that nickel or stainless steel could be used as a negativeelectrode substrate in lieu of the copper, lithium, alu-, minum and RFC mentioned above and that the nega tive electrode substrate could be in the form of a wire, screen or sheet. Nonaqueous batteries constructed from the materials described herein may be either primary or secondary.

What is claimed is:

1. A nonaqueous battery comprising,

a. an electronically conducting cathode formed by reacting pyrolytic graphite with a salt selected from the group consisting of LiClO LiCF SO and; LiBF, to form a compound of pyrolytic graphite and the negative ion of said salt;

b. a lithium anode; and

c. an electrolyte solution made up by dissolving a salt selected from the group consisting of LiClO LiCF SO and LiBF, in a solvent selected from the group consisting of dimethyl sulfite and propylene .....carbonate.

2. A battery according to claim 1 wherein said cathode is formed by the reaction of LiClO, with graphite.

3. A battery according to claim 1 wherein said cathode is formed by the reaction of LiCF SO with graphite.

4. A battery according to claim 1 wherein said cathode is formed by the reaction of LiBF with graphite.

5 Xrfififir r riintihga iiiner of the type described in claim 1, said method comprising the steps of:

an electronically conducting lamellar compound of graphite and the negative ion of said salt is formed as the cathode and Li is deposited on said anode sub trates a 

1. A NONAQUEOUS BATTERY COMPRISING, A. AN ELECTRONICALLY CONDUCTING CATHODE FORMED BY REACTING PYROLYTIC GRAPHITE WITH A SALT SELECTED FROM THE GROUP CONSISTING OF LICLO4, LICF3SO3 AND LIBF4, TO FORM A COMPOUND OF PYROLYTIC GRAPHITE AND THE NEGATIVE ION OF SAID SALT; B. A LITHIUM ANODE; AND C. AN ELECTROLYTE SOLUTION MADE UP BY DISSOLVING A SALT SELECTED FROM THE GROUP CONSITING OF LICLO4, LICF3SO3, AND LIBF4 IN A SOLVENT SELECTED FROM THE GROUP CONSISTING OF DIMETHYL SULFITE AND PROPYLENE CARBONATE.
 2. A battery according to claim 1 wherein said cathode is formed by the reaction of LiClO4 with graphite.
 3. A battery according to claim 1 wherein said cathode is formed by the reaction of LiCF3SO3 with graphite.
 4. A battery according to claim 1 wherein said cathode is formed by the reaction of LiBF4 with graphite.
 5. A method for fabricating a battery of the type described in claim 1, said method comprising the steps of: a. preparing a discharged battery having a pyrolytic graphite cathode, a nonwoven polypropylene cloth separator, an anode substrate selected from the group consisting of lithium metal, copper metal, aluminum metal, nickel metal, stainless steel and graphite and an electrolyte solution made up of a salt selected from the group consisting of LiCF3SO3, LiClO4 and LiBF4 dissolved in a solvent selected from the group consisting of dimethyl sulfite and propylene carbonate; and b. charging said battery to cause a reaction wherein an electronically conducting lamellar compound of graphite and the negative ion of said salt is formed as the cathode and Li is deposited on said anode substrate. 